Woven face PVC floor covering

ABSTRACT

The floor covering includes multiple layers including a non-woven base layer, a VAE precoat applied to the non-woven woven base layer and overlaid by a first PVC layer. A fiberglass mat is applied over the first PVC layer and a second PVC layer is applied over the mat. A woven PVC layer is laminated by heat and pressure to the underlying second PVC layer. The woven PVC layer comprises monofilament or multifilament cores, preferably but not limited to, polyester filaments overlaid by a PVC coating.

BACKGROUND OF THE INVENTION

The present invention relates to a floor or wall covering in tile orroll form and particularly relates to a woven face PVC floor covering.

A principal and inherent deficiency in carpets, particularly incommercial facilities, resides in the declining appearance retention ofthe aesthetic features of the carpet over long periods of use. It willalso be appreciated that carpet construction fabricated to commercialrequirements frequently and typically sacrifices other desirableattributes of carpets or rugs such as comfort underfoot. Another primeconcern in the selection of materials for use in commercial carpeting isthe capacity of the materials to be recycled. Currently, carpet beingreplaced is conventionally transported to landfills which are themselvesbecoming increasingly scarce and very little, if any, of the taken-up orused carpet is recycled.

Further, many of today's commercial carpets have limited strengthcharacteristics. For example, many commercial carpets over time, or uponimpact by certain objects, will delaminate, essentially requiringreplacement of the carpet. Other characteristics of many commercialcarpets also leave much to be desired. For example, many commercialcarpets are formed of polyurethane, which is only moisture-resistant andthus can and do degrade over time. Moreover, in many commercial carpetconstructions, trimming of sprouts of fiber is common. This escalatesthe time required for initial carpet installation and, hence, costs, aswell as often requiring removal of fibers which come loose over time.

BRIEF DESCRIPTION OF THE INVENTION

In accordance with a preferred embodiment of the present invention,there is provided, in one aspect, a modular carpet, e.g., carpet tilesor roll carpet in discrete widths such as six-foot widths, wherein thewear surface of the covering is composed of a material woven with yarnscovered with polyvinyl chloride. For example, the face covering maycomprise yarns consisting of a core of monofilament or PVB or organicpolymer plastic staple polyester coated with PVC. However, it will beappreciated that while a polyester core is preferred, any similar coreyarn would be suitable, e.g., nylon, wool, acrylic, cotton, modacrylic,PLA or other synthetic or natural yarns. Also and advantageously, thePVC can be colored in any number of different shades, affording a widevariety of designs, and may be woven in conventional weaving machinesinto a fabric.

Preferably, the carpeting comprises successive layers of variousmaterials. The base of the carpeting, i.e., the side of the carpetingopposite the face side and in contact with the underlying floor, ispreferably formed of a non-woven material. A layer of VAE pre-coat isapplied to the non-woven material and dried and cured. A first layer ofPVC is then applied on top of the VAE layer, followed by a fiberglassmat on top of the first PVC layer. A second layer of PVC is then appliedover the fiberglass mat and the PVC is then cured by conventionalmethods. Finally, the woven PVC material is laminated to the underlyinglayers as it exits the curing oven. With an embossing roll and the heatof the cured PVC, the two layers of PVC bond to form the final product.The heat and pressure at the embossing station also causes at leastportions of the PVC surrounding the fibers of the woven face layer tocoalesce with and bond to the underlying PVC layers to form a unitarystructure. Consequently, the final carpet is highly stable and has highstrength, as well as high resistance to delamination.

By utilizing the foregoing described materials, approximately 80% of thecarpet is recyclable. Conversely, by using post-consumer/industrialmaterials available on the market, approximately 80% of the final carpetmay be constructed from those post-consumer/industrial waste sources.Moreover, because of the use of PVC, the carpet is 100% impermeable tomoisture and, hence, will not degrade over time with moisture. By usinga yarn consisting of a core monofilament PET yarn with PVC extrudedabout the yarn, post-installation trimming of sprouts of fibers isentirely eliminated, with consequent reduced labor and costs uponinstallation and elimination of unsightly loose yarns over time. Manyother desirable characteristics of the carpet include resistance tostaining, abrasion, fastness and resistance to soiling. It will also beappreciated that the carpet can be provided in roll form, for example,in widths much larger than standard widths, i.e., may be provided inwidths 6-feet wide, enabling easy and less costly installation due tofewer seams and improving the aesthetics as a result of the fewer seams.Because the carpet is fabricated in larger widths, it is also capable ofbeing manufactured in larger tiles than conventional tiles, for example,on the order of 18 and 24-inch wide tiles.

In a preferred embodiment according to the present invention, there isprovided a floor or wall covering comprising a base layer, a VAEpre-coat applied to the base layer, a first PVC layer overlying the VAEpre-coat layer, a non-woven mat overlying the first PVC layer, a secondPVC layer overlying the mat and a woven PVC layer overlying the secondPVC layer and forming a face layer for the covering.

In a further preferred embodiment according to the present invention,there is provided a floor or wall covering comprising a base layer, afirst PVC layer overlying the base layer, a non-woven mat overlying thefirst PVC layer, a second PVC layer overlying the mat and a woven layeroverlying the second PVC layer and forming a face layer for thecovering, said woven layer including yarns having at least one polyesterfilament coated with PVC.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary cross-sectional view of a covering constructedaccording with a preferred embodiment of the present invention;

FIGS. 2A and 2B are enlarged cross-sectional views of respective yarnsuseful in forming the covering hereof;

FIG. 3 is a series of fragmentary cross-sectional views illustrating amethod of forming the covering hereof;

FIG. 4 is a schematic illustration of a covering according to thepresent invention in roll form; and

FIG. 5 is a schematic representation of the covering hereof in tileform.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, particularly to FIG. 1, there isillustrated a covering, generally designated 10, constructed inaccordance with a preferred embodiment of the present invention.Covering 10 is comprised of successive layers in the following orderfrom a base layer to a face layer. The initial or base layer 12 ispreferably formed of a non-woven material, although it will beappreciated that layer 12 may comprise a woven material, a tufted carpetor any other textile or substrate sufficiently rigorous in constructionto be suitable. The non-woven layer 12 may be formed of any one ofnon-woven materials such as polypropylene, nylon and polyester andpreferably is formed of post-consumer recycled polyester. This materialis preferably provided at about 4-40 oz/yd² weight and more preferablyin a range of 8-12 oz/yd². The next layer 14 is preferably a pre-coatlayer of various organic polymers including acrylic, SBR, EVA orpreferably VAE applied to the non-woven material 12. Precoat layer 14 isparticularly useful as it aids in passing various flammability and smoketests required for most commercial carpets. If, however, thoseconsiderations are not a concern, the precoat layer 14 can be omitted.Preferably, the VAE pre-coat is applied to obtain about 4-40 andpreferably 24 oz/yd² and then dried and cured. The third layer 16comprises a first layer of PVC applied on top of the VAE layer. The PVCis preferably applied at a rate to provide about 10-80 and preferablyabout 45.5 oz/yd². A fiberglass mat layer 18 may or may not then beapplied on top of the first layer 16 of PVC. The fiberglass mat may alsobe a Leno weave fiberglass material. Further, the fiberglass mat iseither a non-woven or woven material and is applied at about 0.5-8.0 andpreferably about 2 oz/yd². Applied on top of the fiberglass mat layer 18when used is a second layer 20 of PVC. That is, the initial PVC layerfor some applications may be sufficient. This second layer of PVC isapplied at approximately 10-80 and preferably 45.5 oz/yd², similarly asthe first layer 16 of the PVC. The PVC is then cured via conventionalmethods. Finally, the uppermost or face layer 22 is formed of a wovenmaterial laminated to the underlying layers as they exit the curingoven. With heat and pressure applied by an embossing roll 28 and theheat of the cured PVC, respectively, the two layers of PVC bond to oneanother and to the undersurface of the woven face layer. It will beappreciated that materials other than PVC may be used to bond the layersof the product together. For example, such materials may include PVB,TPOs, APOs, EVA, TPUs (thermal polyurethane), hydrocarbon resins andother organic polymer polyethylenes. However, the introduction of theselatter materials alters undesirably the recyclable percentages of thefinished product.

As illustrated in FIGS. 2A and 2B, the woven face layer 22 is comprisedof yarns 24 that consist of a core monofilament or multifilamentpolyester coated with PVC or other thermoplastic polymers. Thus, in FIG.2A, there is illustrated a core monofilament 26 surrounded by a coatingof PVC material. In FIG. 2B, there is illustrated a staple PET yarn core28 comprising multiple filaments 29, each comprising a core blackmonofilament PET fiber. It will be appreciated, however, that the coresare not limited to polyester, but may include nylon, wool, acrylic,cotton, modacrylic, PLA or other synthetic or natural yarns. Moreover,the PVC can advantageously be colored in any number of shades to providea particular aesthetic design. Further, the yarns may be woven byconventional weaving machines, preferably Dobby or Jacquard machines, toform the fabric.

Referring now to FIG. 3, there is illustrated a method of fabricating acovering in accordance with a preferred embodiment of the presentinvention. First, the non-woven layer 12 is provided with a VAE coat.The VAE coating may be provided in liquid form and dried and cured onthe underlying non-woven layer 12. The pre-coat 14, preferably VAE, isapplied at the above-identified rate. Next, the third layer 16,preferably a PVC layer, is applied on top of the VAE pre-coated layer14. The PVC layer is applied at the above-identified rate. The mat layer18, preferably formed of fiberglass material is then applied over thePVC layer 16 and the second layer 18 of PVC is then applied over themat. The substrate is then passed through an oven 26 where the PVC iscured via conventional methods. Upon emerging from the oven 26, the facelayer 22 of the woven PVC is applied to the final layer 20 of PVC. Thewoven face layer is preferably laminated to the substrate as it exitsthe curing oven. By applying an embossing roll 28 and utilizing the heatof the cured PVC, the two layers 16 and 20 of PVC bond to form the finalproduct. Additionally, the heat and pressure at the embossing stationcauses the PVC of the first and second layers, as well as the PVCsurrounding the fibers on the underside of the woven face layer, tocoalesce with each other to form a unitary structure. Consequently, thefinal product has substantial resistance to delamination.

Referring to FIGS. 4 and 5, the covering 10 may be provided in differentforms. For example, in FIG. 4, the covering is provided in roll form 30,e.g., six feet in width. This enables an easier and less costlyinstallation due to fewer seams. It will be appreciated that fewer seamsalso visually improve the aesthetics of the final installation. Byfabricating the covering in greater widths, i.e., six feet, it is alsopossible to manufacture tiles in 18 and 24-inch widths, which affordsgreater selection in tile dimensions, in comparison with prior arttiles, which are conventionally formed in 18-inch widths. A fragmentaryperspective view of the materials forming the covering 10 in the form ofa tile 32 is illustrated in FIG. 5.

The materials employed in the fabrication of the covering 10 enableapproximately 80% of the final product to be recyclable. Conversely, byusing post-consumer/industrial materials of a similar nature andavailable on the market, the covering may be constructed fromapproximately 80% of those post-consumer/industrial waste sources. Incomparative testing with prior coverings, it has been found that thepresent covering will not delaminate using standard ASTM testing,whereas prior art coverings do delaminate. Also, the breaking strengthof the present covering, again tested by standard ASTM testing, hasapproximately twice or greater the strength as compared with the priorcoverings. It will also be appreciated that the covering is 100%impermeable to moisture as it is constructed substantially entirely ofPVC materials. Additionally, with the PVC extruded about the polyesterfilament cores, the prior necessity for post-installation trimming ofsprouts of fiber as common with prior art coverings is entirelyeliminated. Moreover, the coalescence of PVC along at least theundersurface of the face layer with the underlying PVC enhances theelimination of loose fibers at the seams. Other characteristics of thecovering, such as staining, abrasion and soil resistance, as well asfastness, provide a superior covering to those of prior art.

The floor covering described above has been exhaustively tested at anindependent laboratory for various characteristics, as follows:

Flooring Radiant Panel Test

Specimens Nos. 1-3 of the covering described above were prepared andtested in accordance with ASTM E 64899 and/or Federal Test Method 372.NFPA 253. Test Results Specimen No. 1 Specimen No. 2 Specimen No. 3Critical .74 watts/cm² .51 watts/cm² .69 watts/cm² Radiant Flux TotalBurn 28.0 cm 39.0 cm 30.0 cm Length Flame Front 19.0 minutes 30.0minutes 13.0 minutes OutAverage critical radiant flux .65 watts/cm²Smoke Density Test (NIST)

Specimens Nos. 1-3 were prepared and tested in accordance withprocedures proposed by the National Institute of Standards andTechnology (formerly National Bureau of Standards). Technical Note 708and NFPA 258, ASTM E 662-97 Operating Conditions Irradiance: 2.5watts/cm² G Factor 132 Thermal Exposure: Non-flaming Furnace Voltage:104 Test Results #1 #2 #3 Average Chamber Temperature, ° F. 95 95 95(start) Chamber Pressure Maintained positive, under 3″ H₂O MinimumTransmittance (TM), % 1% 1% 2% at, minutes 13.00 16.00 16.00 15.00Maximum Specific Optical 924 924 885 911 Density (DM) Clear Beam (DC) 5582 75 71 DM, CORRECTED (DMC) 869 842 810 840 Specific Optical Density at2 1 2 2 1.5 minutes Specific Optical Density at 113 117 132 121 4.0minutes Time to 90% DM, minutes 10.40 12.00 12.00 11.47 Time to DS = 16,minutes 2.50 2.40 2.20 2.37Smoke Density Test (NIST)

Specimens of the submitted sample were prepared and tested in accordancewith the procedures proposed by the National Institute of Standards andTechnology (formerly National Bureau of Standards, Technical Note 708and NFPA 258, ASTM E 662-97. Operating Conditions Irradiance: 2.5watts/cm² G Factor 132 Thermal Exposure: Flaming Furnace Voltage: 102Burner Fuel Propane Test Results #1 #2 #3 Average Chamber Temperature, °F. 95 95 95 (start) Chamber Pressure Maintained positive, under 3″ H₂OMinimum Transmittance (TM), % 14% 22% 12% at, minutes 14.20 10.20 13.0012.47 Maximum Specific Optical 509 747 518 591 Density (DM) Clear Beam(DC) 31 26 35 31 DM, CORRECTED (DMC) 478 721 485 561 Specific OpticalDensity at 172 132 145 150 1.5 minutes Specific Optical Density at 311405 315 344 4.0 minutes Time to 90% DM, minutes 10.20 7.40 10.40 9.33Time to DS = 16, minutes 0.80 0.90 0.90 0.87Foot Traffic Cycles

Test Method Conducted ASTM D 6119 Practice for Creating SurfaceAppearance Changes in Pile Yarn Floor Covering From Foot Traffic CRITM-100 Creating Surface Appearance Changes in Pile Yarn Floor CoveringFrom Foot Traffic CRI TM-101 Assessment of Carpet Surface AppearanceChange Using the CRI Reference Scales

Scope

This practice covers the trafficking of pile yarn floor coverings in alaboratory in order to effect a change in surface appearance as a resultof exposure to foot traffic under controlled conditions. A separate testmethod covers the assessment of surface appearance change using the CRIReference Scales Foot Traffic Specimen ID Cycles Rating Length RatingWidth Sample 20,000 5.0 5.0 described above Average 5.0Key to Ratings5 Negligible or no change4 Slight Change3 Moderate Change2 Considerable Change1 Severe ChangeHexapod Test

Test Method Conducted ASTM D-5252 Hexapod Drum Tester ISO/TR 10361Hexapod Tumbler Ratings Based on CRI TM-101 Photographic Scales

Apparatus: Wire Instrumentation Hexapod Tumbler Carpet Tester

Procedure

The test specimen described above was subjected to the reported cyclesof “Hexapod” tumbling, removing the specimen every 2,000 cycles forrestoration by vacuuming.

An Electrolux upright vacuum cleaner (Discovery II) was used, makingfour (4) forward and backward passes along the length of the specimen.

The samples were assessed using daylight equivalent vertical lighting(1500 lux). Samples were viewed at an angle of 45 degrees from 1½ meterdistance, judging from all directions.

The samples were also measured for pile height before and after testingto obtain a pile height retention value. OVERALL NUMBER OF APPEARANCECOLOR PILE HEIGHT HEXAPOD SAMPLES CHANGE CHANGE RETENTION 4,000 5 5 N/A12,000 5 5 N/AKey to Ratings5 = Negligible or no change4 = Slight change3 = Moderate change2 = Considerable change1 = Severe changeAbrasion

Test Method Conducted ASTM D 3884 Abrasion Wheels —H-18 with 1000 gramsload

Procedure

The sample was abraded until the primary backing was visible which isconsidered the “End Point.”

Wear Cycles for sample of 1500.

AACHEN Dimensional Stability

Test Method Conducted ITTS 004 AACHEN Dimensional Stability

Purpose and Scope

This test procedure measures the dimensional stability of textile floorcoverings both modular and broadloom when subjected to varied moisture,heat and dry conditions. The test specimen corresponded to the preferredembodiment of the covering disclosed above. Test Condition MeasurementPercent Change M₀ 18.0025″ −0.014 MT₁ 18.0000″ +0.035 MT₂ 18.0088″−0.111 MT₃ 17.9825″ −0.049 MT₄ 17.9938″ −0.0087″ C₀ 17.9875″ CT₁17.9825″ −0.028 CT₂ 17.9900″ +0.014 CT₃ 17.9725″ −0.083 CT₄ 17.9725″−0.083Test Condition KeyM₀ Machine Direction Original MeasurementC₀ Cross Direction Original MeasurementT₁ Two (2) hours in an oven at 60° C.T₂ Two (2) hours in a 1% solution at 20° C.T₃ Twenty-four (24) hours in an oven at 60° C.T₄ Forty-eight (48) hours in standard climate at 21° C. & 65% RHASTM F 137 Flexibility

A test specimen as described above was placed over a mandrel with thewearing surface face out. At the completion of the bending operation,visual examination was made for breaks, cracks, or other damage. Thesample passed.

Delamination

Test Method Conducted ASTM D 3936 Delamination Strength of SecondaryBacking of Pile Floor Coverings

Scope

This method determined the delamination strength of secondary backingadhered to the finished pile floor covering of the test specimendescribed above. No separation was detected.

Breaking Strength

Test Method Conducted ASTM D 1667 Breaking Strength

The sample tested corresponded to the preferred embodiment describedabove. Test Results Results Length (lbs.) Results Width (lbs.) 500.128500.044 500.172 499.700 500.064 500.023 500.130 500.013 200.044 500.014500.108 499.959Resistance to Chemicals

Test Method Conducted ASTM F 925 Standard Test Method for Resistance toChemicals of Resilient Sheet Flooring

The sample tested corresponded to the preferred embodiment describedabove.

Scope

This method provides a procedure for determining the resistance ofresilient sheet vinyl floor covering to surface deterioration whenexposed to various chemicals. This test method is not intended as astaining test. Categories for rating are surface dulling, surface attackand color change. Chemical Test Agent Immediate Rating 24 Hour RatingWhite Vinegar — No Change Rubbing Alcohol — No Change White Mineral Oil— No Change Sodium Hydroxide — No Change Solution Hydrochloric Acid — NoChange Solution Household Ammonia — No Change Solution Household Bleach— No Change Solution Disinfectant — No Change Unleaded Gasoline — NoChangeKey to RatingNo changeSlight changeModerate changeSevere changeStain Resistance

Test Method Conducted AATCC Test Method 175 Stain Resistance

Procedure

The test sample(s) described above were subjected to staining inaccordance to the test procedure. The evaluations are reported below,staining scale members indicate 10 being no apparent stain and 1 being avery severe stain.

Test Results: Rating

-   -   10        Accelerated Soiling

Test Method Conducted ASTM D 6540 Standard Test Method for AcceleratedSoiling of Pile Yarn Floor Covering

Purpose and Scope

This test method describes the equipment, and the test method forassessing the propensity of pile yarn floor coverings to early soilingusing a standard artificial soil composition.

Purpose

The above-identified covering specimens were secured to a backing sheetmounted inside a Hexapod drum with the pile surface exposed, and weresubjected to an accelerated soiling process. The degree of soiling wasmeasured or assessed by comparing the change in color between soiled andoriginal pile yarn floor covering, using a measurement device orvisually using AATCC Gray Scales. Test Results Sample Rating Ratingafter soiling/before cleaning 4 Rating after soiling/after cleaning** 5*Type of soil used: AATCC 123 **Type of cleaning used: Hot WaterExtractionKey to Ratings5 Negligible or no change4 Slight change3 Noticeable change2 Considerable change1 Severe changeElectrostatic Propensity

Test Method Conducted AATCC 134-1996 Electrostatic Propensity of Carpets

Purpose and Scope

This test method is designed to assess the static generating propensityof carpets developed when a person walks across them by controlledlaboratory simulation of conditions which may be met in practice, andmore particularly, with respect to those conditions which are known fromexperience to be strongly contributory to excessive accumulation ofstatic charges. The specimen used corresponds to the preferredembodiment identified above. Test Conditions: Chamber Temperature: 70°F. Chamber Relative Humidity: 20% Maximum Maximum Voltage VoltageAverages Test Results Sole Underlay 1 (kV) 2 (kV) (kV) Test I Step TestNeolite Plate Neg. 1.8 Neg. 1.5 Neg. 1.7 Test II Step Neolite Plate Pos.1.9 Pos. 1.9 Pos. 1.9 Test Test III Step Leather Plate Pos. 0.1 — — TestTest IV Scuff Leather Plate Pos. 1.0 — — TestSoles:a) Neolite XS 664b) Suede LeatherUnderlayment:a) Plate: Earth grounded metal plateb) H/J: Standard 40 oz/yd2 rubberized Hair/Jute cushionStatic Coefficient of Friction

Test Method Conducted ASTM C-1028 Static Coefficient of Friction

Test Method Summary

The above-identified specimen submitted was subjected to testing inaccordance to the test procedure. The results are reported below: TestResults Dry Coefficient of Friction Wet Coefficient of Friction 1)0.80 1) 0.71 2) 0.80 2) 0.76 3) 0.78 3) 0.78 4) 0.82 4) 0.71 5) 0.81 5)0.78 6) 0.81 6) 0.76 7) 0.82 7) 0.74 8) 0.80 8) 0.78 9) 0.83 9) 0.7910)  0.83 10)  0.76 11)  0.80 11)  0.76 12)  0.82 12)  0.74 Average0.8108 Average: 0.7548 F_(D) = (R_(D)/N_(W)) = X_(D) F_(W) =R_(W)/N_(W)) + X_(W)F_(D) = static coefficient of friction for dry surfaceF_(W) = static coefficient of friction of wet surfaceR_(D) = total of the 12 dry force readings (lbs.)R_(W) = total of the 12 wet force readings (lbs.)N = number of pulls (12)X_(D) = dry calibration factorX_(W) = wet calibration factorW = total weight of the heel assembly plus 50 lb. weightRoll Chair Testing

Test Method Conducted ITTS-205 Roll Chair Testing

Purpose and Scope

This test method is designed to measure the appearance retention ofcarpet when exposed to roll chair (office chair) exposure.

Procedure

A specimen of the above sample was installed on a wood substrate andexposed to the reciprocating action of an office chair, loaded with 150pounds, impelled at approximately 14 cycles per minute. The specimen wasexposed to the indicated number of cycles and rated in accordance to thescale below. Rating Appearance of Carpet in Caster Traffic Region 5 -Excellent Negligible or no change 4 - Good Slight change in appearance,due more to disturbance of the pile than to matting. Visible change 3 -Fair Noticeable change in appearance. Some matting of the pile 2 - PoorConsiderable change in appearance. Pile yarns either disturbed or packedand matted 1 - Very Poor Severe change in appearance. Pile yarns packedwith severe crushing Comments Number of Cycles Rating 10,000 4.5Heat Aging

Test Method Conducted Heat Aging

Procedure

The covering described above was subjected to heat aging at 158° F. forfourteen (14) days. After the aging time, a visual assessment was madeas to the discoloration and brittleness of the test specimen both frontand back.

Test Results: No brittleness or discoloration of face or back

Colorfastness to Light

Test Method Conducted AATCC Test Method 16 Option E Colorfastness toLight (Water-Cooled Xenon Arc)

Purpose and Scope

This test method provides the general principles and procedures whichare currently in use for determining the colorfastness, to light oftextile materials.

Procedure

Samples of the above-identified covering to be tested and theagreed-upon comparison standard(s) are exposed simultaneously to a lightsource under specified conditions. The colorfastness to light of thespecimen is evaluated by comparison of the color change of the exposedportion to the masked or control portion of the test specimen using theAATCC Gray Scale for Color Change or by instrumental color measurement.Test Specimen Number of Indication Cycles Rating See Above 2 (40 AFU's)5Key to Ratings5 Negligible or no change4 Slight change3 Noticeable change2 Considerable change1 Severe changeColorfastness to Ozone Under High Humidities

Test Method Conducted AATCC Test Method 129 Colorfastness to Ozone UnderHigh Humidities

Purpose and Scope

This test method is used for determining the resistance of the color oftextiles to the action of ozone in the atmosphere at elevatedtemperatures with relative humidities above 85%.

Procedure

A test specimen corresponding to the above-identified preferredembodiment and a swatch of control sample were simultaneously exposed toozone in an atmosphere which is maintained at 87.5±2.5% relativehumidity and a temperature of 40±1C (104±2F) until the control sampleshowed a color change corresponding to that of a standard of fading. Thecycles were repeated until the specimen showed a definite color changeor for a prescribed number of cycles. Test Specimen Number of IndicationCycles Rating See Above 2 5Key to Ratings5 Negligible or no change4 Slight change3 Noticeable change2 Considerable change1 Severe changeColorfastness to Burnt Gas Fumes

Test Method Conducted AATCC Test Method 23 Colorfastness to Burnt GasFumes

Purpose and Scope

This test method is intended for assessing the resistance of the colorof textiles of all kinds and in all forms when exposed to atmosphericoxides of nitrogen as derived from the combustion of natural gas.

Procedure

A specimen of the above-identified covering and the test control fabricwere exposed simultaneously to oxides of nitrogen from burnt gas fumesuntil the control showed a change in color corresponding to that of thestandard of fading. The change in color of the specimen was assessedwith the standard gray scale for assessing change in color. TestSpecimen Number of Indication Cycles Rating See Above 3 5Key to Ratings5 Negligible or no change4 Slight change3 Noticeable change2 Considerable change1 Severe change

While the invention has been described in connections with what ispresently considered to be the most practical and preferred embodiment,it is to be understood that the invention is not to be limited to thedisclosed embodiment, but on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the appended claims.

1-20. (canceled)
 21. A method of manufacturing a floor or wall coveringcomprising the steps of (a) forming a substrate by (1) providing anon-woven polyester base layer; (2) applying a liquid vinyl acetateemulsion pre-coat to the base layer; (3) drying and curing the pre-coatlayer on the base layer; (4) applying a first polyvinyl chloride layerto the vinyl acetate emulsion pre-coat layer; (5) applying a non-wovenmat to the first polyvinyl chloride layer; and (6) applying a secondpolyvinyl chloride layer to the mat; (b) passing the substrate throughan oven to cure the polyvinyl chloride layers; and (c) laminating aprestabilized woven polyvinyl chloride layer to the substrate to form aface layer for the covering.
 22. A method according to claim 21,including applying pressure to the floor or wall covering to bond thepolyvinyl chloride layers to one another.
 23. A method according toclaim 21, including forming said mat of fiberglass.
 24. A coveringaccording to claim 21, including bonding the polyvinyl chloride layersto one another.
 25. A method according to claim 21 including integrallybonding the polyvinyl chloride layers to one another.
 26. A methodaccording to claim 21 including bonding the woven polyvinyl chloridelayer to said second polyvinyl chloride layer.
 27. A method according toclaim 21 including forming the woven polyvinyl chloride layer to includeyams having at least one polyester filament precoated with polyvinylchloride.
 28. A method according to claim 21 including forming the wovenpolyvinyl chloride layer to include a core yarn formed of amultifilament polyester coated with polyvinyl chloride.
 29. A methodaccording to claim 21 including forming the woven polyvinyl chloridelayer to include at least one core yarn coated with polyvinyl chloride.30. A method according to claim 21 including forming the woven polyvinylchloride layer to include yarns having a monofilament core.
 31. A methodaccording to claim 21 including forming the woven polyvinyl chloridelayer to include yarns having a multifilament core.
 32. A methodaccording to claim 21 including forming the woven polyvinyl chloridelayer to include yarns coated with polyvinyl chloride and selected fromthe group consisting of a polyester, nylon, wool, acrylic, cotton,modacrylic, polylactic acid.
 33. A method of manufacturing a floor orwall covering comprising the steps of: providing a non-woven polyesterbase layer; applying a first polyvinyl chloride layer overlying the baselayer; applying a non-woven mat overlying the first polyvinyl chloridelayer; applying a second polyvinyl chloride layer overlying the mat; andapplying a woven layer having yarns including at least one polyesterfilament coated with polyvinyl chloride overlying the second polyvinylchloride layer to form a face layer for the covering.
 34. A methodaccording to claim 33 including forming said mat of fiberglass material.35. A method according to claim 33 including bonding the first andsecond polyvinyl chloride layers to one another.
 36. A method accordingto claim 33 including providing the woven layer with a core formed of amultifilament polyester coated with polyvinyl chloride.
 37. A methodaccording to claim 33 including selecting the yarns from the groupconsisting of a polyester, nylon, wool, acrylic, cotton, modacrylic andpolylactic acid.
 38. A method according to claim 32 including applying apre-coat overlying and in contact with the base layer, forming the baselayer to include a non-woven polyester, providing the non-woven baselayer and the pre-coat each to a weight of 4-40 oz/yd2, providing thefirst and second polyvinyl chloride layers to each have a weight of10-80 oz/yd2.
 39. A method according to claim 38 including providingsaid non-woven base layer and the pre-coat in weights of 8-12 oz/yd2 andabout 24 oz/yd2, respectively, providing said first and second polyvinylchloride layers each having weights of about 45.5 oz/yd2, forming saidmat of a fiberglass material.